Ergonomic abrasive pad assembly

ABSTRACT

The abrasive pad is removably affixed to the first end and configured to be easily adjustable by release of a hook and loop connection arrangement affixing the abrasive pad to the plate. The grip end and the abrasive pad end of the plate are separated by a specific angle medial bend which facilitate use of the tool in an ergonomic manner. The tool includes a rectangular plate having a first end wrapped with an adjustable abrasive pad and a second grip end. The plate is in the form of a rectangular, parallelepiped with a medial bend between the first end and second end.

CROSS REFERENCE TO RELATED APPLICATION

This is a utility application based on provisional application Ser. No. 62/425,384 filed Nov. 22, 2016 entitled “Ergonomic Abrasive Pad Assembly” which is incorporated herewith and for which priority is claimed.

TECHNICAL FIELD

An automotive repair tool for internal combustion engine repair.

BACKGROUND

In a principal aspect the present invention relates to a manual abrasive pad tool for deburring machine parts and which is especially useful for abrading metal surfaces following removal of seals and gaskets from generally flat surfaces of component parts of an internal combustion engine or other machine parts.

When repairing automobiles and, in particular, automotive engines, a mechanic may discover the necessity to disassemble the engine components such as cylinder heads from the engine block. Typically such components are separated by sealing gaskets designed to prevent fluid or gas leakage from the engine and to insure proper operation of the engine. Thus, when repairing vehicles or other installations using internal combustion engines, it is often necessary to remove the gaskets and seals and replace them with new gaskets or seals upon reassembly of the engine. Removal of gaskets can be effected by spatulas and, in some instances, deburring devices which may be electrically operated and are designed to rotate a disc pad to engage the gasket and effect its removal from a surface of the engine component. In such circumstances, however, dust and grit is generated. Additionally, the gasket may be positioned on a surface with right angle or other angle corners thus making it quite difficult to position the spatula or a rotary deburring device in order to effect total removal of the gasket and polishing of the remaining surface of the engine component.

Thus, there has developed a need for an improved special purpose deburring or residual gasket removal tool which is ergonomic yet can be used efficiently in confined spaces for removal of residual gasket material and grit on surfaces having various configurations. Heretofore, there have been various types of apparatus proposed for seal removal or similar tasks including the following:

Patent/ Publication No. Inventor(s) Title Issue Date 6,048,257 Greenman Abrasive Pad Holder Apr. 11, 2000 et al. 5,426,810 Rones Abrasive Pad Holder Jun. 27, 1995 4,454,624 Vandermer Scouring Pad Holder Jun. 19, 1984 4,222,204 Benner Holder for an Abrasive Sep. 16, 1980 Plate 4,071,983 Thielen Griddle Cleaning Pad Feb. 7, 1978 Holder 3,527,001 Kleemeier Holder for Abrasive Jun. 1, 1967 et al. Product 1,832,068 Watkins Steel Wool Pad and Nov. 17, 1931 Holder 1,143,725 Reed Pad Holder Jun. 22, 1915 US2004/0048561 Brinkmann Sanding Tool for Mar. 11, 2004 Moldings of Wood or the Like US2004/0255417 Young Mop Head with Dec. 23, 2004 Abrasive Pad or Sheet

While the foregoing may be useful, such tools or devices often fail to timely remove residual gasket material and grit in an efficient manner that effectively polishes the surface of a component.

SUMMARY

Briefly the present invention comprises an ergonomic, abrasive pad assembly designed to remove seals and gaskets, particularly residual materials and grit, from generally flat surfaces located in difficult to access locations. The abrasive pad assembly includes the combination of a metal handle formed from a unitary rectangular flat metal plate which includes a bend intermediate the opposite ends of the metal plate. The forward end of the plate provides a receiving section for a pad construction which includes a layer of polymeric hook material folded over the forward end of the plate and adhered to the opposite flat sides of the plate with a polymeric hook element facing outward from the opposite surface sides of the plate. The pad assembly further includes an abrasive pad having loops of polymeric material on an interior surface or inside face of the pad designed to be wrapped over the hook material affixed to the opposite sides of the plate. The loop material component thus engages, supports and exposes an adjustable abrasive outer pad layer facing outwardly from both sides of the plate and over the distal end of the pad receiving end of the handle. The position of abrasive pad may be longitudinally adjusted by altering longitudinal engagement of the loop material affixed to the abrasive pad with the hook material and affixed on the surface of the receiving end of the handle. This arrangement will enable a mechanic to adjust the abrasive pad or replace the pad on the receiving end of the handle, depending upon the particular task being performed and the location of the surface which is to be abraded or polished.

Thus it is an object of the invention to provide a unique and useful tool for the removal of gaskets and similar debris items from a generally flat metal surface and polish that surface.

It is a further object of the invention to provide an abrasive pad construction wherein the pad may be removed and replaced as necessary due to use.

A further object of the invention is to provide an abrasive pad wherein the abrasive section of the pad is combined with a loop material cooperative with a hook material adhered to the receiving end of the tool and wherein the elements comprising the pad as well as the hook material and loop material are adjustable yet substantially of the same configuration and compatible dimension as the receiving end of the handle in order to facilitate placement of abrasive pressure efficiently by manual adjustment of the pad on the tool and operation of the tool.

A further object, advantage and feature of the invention is to provide an improved tool assembly including a handle, replaceable generally rectangular configured abrasive materials and an adjustable structure which may be subjected to abuse.

Another object of the invention is to provide an abrasive handle and pad construction or assembly which is easy to use, is reasonably priced and is rugged.

These and other objects and advantages and features are set forth in the detail description which follows.

BRIEF DESCRIPTION OF THE DRAWINGS

In the detail description which follows reference will be made to the drawing comprised of the following figures:

FIG. 1 is a side elevation view of the tool of the invention;

FIG. 2 is a side elevation of the metal handle or plate which is incorporated in the tool of FIG. 1;

FIG. 3 is a top plan view of the handle component of FIG. 2;

FIG. 4 is a side elevation of an abrasive pad which is incorporated in the tool of the invention;

FIG. 5 is a top plan view of the pad of FIG. 4;

FIG. 6 is a plan view of a hook strip of material with an adhesive backing which is adhered to the forward receiving end of the handle of the tools;

FIG. 7 is a plan view of a grip which is designed to fit on the handle section of the tool of FIGS. 1; and

FIG. 8 is an end view of a pocket of the grip of FIG. 7.

DESCRIPTION OF AN EMBODIMENT OF THE INVENTION

Referring to FIG. 1, a side elevation view of the tool of the invention is depicted including a handle or plate 10 having a grip end 12 and a forward pad receiving end 14. The handle 10 is formed from a metal plate having a rectangular, parallelepiped configuration as depicted in FIG. 3. The plate 10 thus is shaped to include a bend 18 connecting the grip end 12 with the abrasive pad receiving end or section 14. Typically, the bend 18 provides an included obtuse angle in the range of 150°±15° between the forward pad end 14 and the handle grip end 12 as depicted. A typical longitudinal length dimension of the pad receiving end 14 is 2-4 inches. The plate 10 includes a top side 28 and a bottom side 30. A lateral side of the handle 10; namely, forward side sections 20, 22, and rearward or grip side sections 24 and 26 are flat and planar. Opposite forward end side 23 and rearward grip end side 25 are generally perpendicular to the top side 28 and bottom side 30 of the handle 10. The handle 10 thus has a uniform cross sectional configuration in the longitudinal direction or along axis 31 between opposite ends 23 and 25 which facilitates the placement of the tool in spaces which are restricted and thereby enables access for efficient manual movement of the tool by means of gripping the handle 10 at the grip end 12. However, the forward end side sections 20, 22 may be spaced less than or greater than the rearward grip end sides 24, 26 or vice versa to provide a tool for a specific deburring and polishing task.

Referring to FIGS. 4 and 5, there is depicted an abrasive component 32 of the unitary pad construction. Abrasive component 32 includes an abrasive pad 36 which is adhered to a loop material layer 38 formed of elastic polymeric material. The longitudinal dimension of the forward end 14 of the handle 10 is substantially and typically 1.0 to 2.0 times the longitudinal length of the abrasive pad component 32. The length and width and shape of the abrasive pad 36, however, is coterminous with a loop material layer 38 affixed to the underside of the abrasive pad 36.

FIG. 6 depicts a separate hook material layer 44 which has the same lateral or side to side size and dimension as the pad component 32 of FIGS. 4 and 5. However, the longitudinal dimension of the hook material 44 is, in the embodiment depicted, 1.0 to 2.0 times the longitudinal dimension of the abrasive pad component 32. The hook material 44 is wrapped around the end side 23 and includes polymeric hooks which extend outwardly from the top and bottom surfaces of the hook layer 44 at the receiving end 14 of the plate 10. The hook layer 44 has an outwardly projecting hook surface pattern and adheres by means of adherent or adhesive material on an inside surface to hold the hook material layer 44 on the receiving end section 14.

The hook material 44 interacts with the loop material 38 as shown in FIG. 4. A trade name of a typical hook and loop assembly is Velcro. As a result, the abrasive pad component 32 (which is shorter longitudinally than hook element 44) may be adjusted longitudinally with respect to the manner in which it folds over the hook material 44 of the pad receiving section or receiving end 14 of the tool. That is, as the pad component 32 wears, it may be necessary to move the pad component 32 from the pad receiving end 14. Additionally, as the pad component 32 is utilized certain parts of it may wear move quickly than other parts. Thus, replacement and/or adjustment of the pad construction 32 may be appropriate and necessary from time to time.

Because the longitudinal dimension of the hook material 44 may or typically will exceed that of the pad component 32, locking engagement of the pad component 32 along its entire longitudinal dimension thereof is assured upon repositioning of the pad 32 on the hook material 44 of the receiving end 14. Adjusting the pad component 32 enables exposure of select portions of the pad 32 on both sides of the pad support section 14 to more efficiently engage a gasket to effect removal thereof. Further, by carefully matching the lateral or side to side dimensions of the loop component of FIGS. 4 and 5 with the size of the pad support hook layer 44 and the receiving end 14, manual operation of the handle 10 at grip end 12 becomes more effective inasmuch as the force from the pad support section is uniform and thereby may be effectively positioned in otherwise very difficult places to access. This is especially so with respect to right angle corners which are often in recessed positions of flat surfaces designed to place a gasket of a vehicle. In such a circumstance, a rotary gasket removal tool is not adequately efficient. Thus, the adjustability of the assembly of the abrasive pad component 32 by adjusting the position of the hook loop material 38 provides an easily and quickly adjustable assembly designed to efficiently position the pad component 32 on the pad receiving end 14 of the handle 10.

FIGS. 7 and 8 depict the grip 50 which comprises a sleeve having a pocket 52 at one end so that the grip 50 may fit over and be retained on grip end 12.

The following Table 1 sets forth dimensions and design parameters of a version of the subject matter of the invention.

TABLE 1 DESCRIPTION DIMENSION Thickness of handle 10  .18 ± .06 Length of handle 10 6 to 9 inches Width of handle 10 1.00 ± .12 Length of pad 36 4.00 ± .25 Width of pad 36 1.00 ± .12 Length of hook element 44 4.00 ± .25 to 5.00 ± .25 Width of hook element 44 1.00 ± .12 Specification for hook/loop material Velcro Loop with Medium Pad

Alternative longitudinal length combinations of abrasive pad component 32 and hook element 44 may provide a useful polishing tool. For example, the longitudinal dimensions of abrasive pad component 32 and hook member 44 may be equal or nearly equal. Neither component should extend beyond the bend to avoid undesired engagement or interference with wires or other mechanical components. Thus, the length of the engagement end 14 may typically vary between 2 inches and 5 inches. A set of such polishing tools may thus be created to enable use of such an adjustable tool for unique tasks and situations.

In sum, the combination of the handle 10 having the described handle shape and dimensions with a specific size and shape of an abrasive pad component with an abrasive pad 36, a polymeric loop layer 38 and a polymeric hook layer 44 correlated in shape and size with each other and the handle, results in an ergonomic adjustable pad assembly especially useful to remove material such as a gasket grit residue or layer from a flat surface having corner sections with limited access for an abrasive tool. An important aspect of the invention is positioning of a hook layer 44 having a greater longitudinal length than the abrasive pad section 32. Hook element 44 is affixed to the pad receiving end 14 and extends preferably to the bend 18 or beyond on both the top side 28 and bottom side 30 of the handle 10 at the pad assembly and receiving end 14. This enables adjustability and efficiency of the placement of the pad or abrasive component 32. The placement of the hook material vis-a-vis the loop material is a preferred embodiment. However, they may be reversed or replaced by equivalent fastening systems if necessary for technical reasons.

While there has been set forth an embodiment of the invention it is to be understood that the invention is limited only by the following claim and equivalents thereof. 

What is claimed is:
 1. An ergonomic, abrasive polishing pad assembly for use by technicians to effectively remove residual seal or gasket material from generally flat surfaces of component parts of internal combustion engines and for deburring engine and machine parts comprising, in combination: a handle formed from a single flat, unitary, rectangular, parallelepiped metal plate, said plate having a longitudinal axis, a longitudinal length dimension, a width dimension, a uniform thickness, said length dimension in the range of 6 to 9 inches, said width dimension in the range of ⅞ to 1¼ inches and a thickness in the range of 0.1 to about 0.2 inches, said handle including a top surface, a bottom surface, a planar front side, a planar back side, said front and back sides generally perpendicular to the top surface and the bottom surface, said handle further including longitudinal, parallel side surfaces perpendicular to the top side and bottom side surfaces, said side surfaces parallel to each other, said handle including a forward end abrasive pad assembly receiving section joined to a rearward grip section and said pad assembly receiving section, and said rearward grip section joined by an obtuse angle bend of said metal plate, said bend having a radius of 0.5±0.10 inches and forming an obtuse angle in the range of 150°±15°; a rectangular, polymeric, hook member including a hook surface on one side and an adhesive surface on said opposite side, said adhesive surface opposed side adhered on the receiving section of the plate and extending generally from the bend on the bottom surface of the plate receiving side, over the forward end and onto the top surface of the receiving end and terminating at or short of the bend, said hook member having a width substantially equal to the width between the side surfaces +0.3%-0.0% of the span between the longitudinal side surfaces of the plate receiving end; and a removable, flexible, rectangular, polymeric loop pad including a top surface comprising an outer abrasive material face mounted on a co-terminus polymeric loop material with a bottom loop face, said loop material bottom loop face releasably joined to the hook member outer face, said loop pad substantially the same lateral dimension as the hook pad in width and greater than the longitudinal length dimension of the receiving end of the plate; and a removable handle grip member on the grip section, said handle grip member formed from an elastomeric material with an internal pocket, an opening at one end of said grip member, said grip member fitted on the grip receiving section.
 2. The polishing pad assembly of claim 1 wherein the longitudinal dimension of the hook pad and loop pad are substantially equal length.
 3. The polishing pad assembly of claim 1 wherein the loop pad has a longitudinal length dimension no more than about 85% of the longitudinal length dimension of the hook pad. 